Mahufacttjke



w. H. wo Dee. 4, 1928. OD

' uANUFAcTURE 0F HEADLIGHTS 2 sheets-sneed Original Fileu Aug. l?, 1923 ---10J fig 2 vWl LL'IAM H. WOOD InvE NToR,

ATTORNEYS W' H W R.'17,155 Dec 4, 1928. 'umumc'ruas or sADLreHTs a sheets-sheet 2 Original Filed Aug. 17, 1925 WILLIAM H. Woon INVENToR y ATTORNEYS kReissued Dec. 4, 11928.

,UNITED .Sr

' ^Re.17,155f

PATENT oF FICE.

n, y ,MANUFACTURE oF HEADLIGHTS.

` Qrignal No. 1,668,706, dated. May 8, 19.7.18,Sera1 No. 657,996, led August 17, 1923. Application for reissue led Junell, 1928. Serial No. 284,628.

This invention relates tovehicle headlights and has for its object theprovision f a new and improved punch and die whereby` `a one` piece sheet metalretlector can be simply and `5 easily made which shall produce a legallyv acceptable and practically satisfactory dis'-v tribution of light without the use of lenses,

v, prisms, shades, dimmers or other expensive, -fragile, or light killing devices. Other obl' of the invention relate to the production of'sucha punch and die each from a single piece of metal; the provision of apunch of `such construction `t-hat it can readily be dressed or re-shaped; the provision of afde- '15 vice of this character which can'be very quickly and cheaplv produced; the provision of an improved headlight reiiector, while further objects and advantages of the invention will `become apparent as the description 20 proceeds. p.

- In my `former application tiled J an. 24, 1,923, Serial No.` 614,694 I described a certain mathematical surface for use in the construction of headlight reflectors for produc- 95 ing a light which isnot only legally satisfactory, but alsoto a considerable extent independent of minor variations `in focal distance. The present invention contempla-tes the use of these curves, or other curves simmannerof impressing these curves upon the 1 metal blocky whereby the too-l itself is produced. In the drawings accompanying and 4forming a part of this application wherein portionv of my reiector;- Fig.` 24 showsy theb mode of generating my yimprovedrcurve asV employed forthe lowerpart of my reflector: Fig. 3` is adiagrammatic view showlng the preferred mode of assemblingr these curves together and disposing them with reference to Ithe horizontal, this diagram conforming substantially to the ,central vertical section of my preferred reiector; Fig. 4 illustrates .therst step in the preparation .of my improvedrefiector punch; Fig. 5 represents the second .,step; Fig. 6k isa face vieur of the punch-shown iny Fig. 5; Fig. 7' illustrates the same punch at. the conclusion of the next f step; Fig. 8 is a face viewl of thepunch in Fig.' 7: lf

after iitvmg` had. the `first eut takenftif its ilarlyhfound, but refers specifically to the g. `9 illustrates the samepuneh upper part; Fig. 1()v is a. face `view of the*` punch shownin Fig. 9; Fig. 11 shows the same punch after having had the next cut' taken ofi' its upper portion; Fig. 12 is a front view of the ,punch shown in Fig. 11; also' illustrating the nature of the next succeeding step;` Fig. 13 is `a side elevation of` the completed punch; Fig. 14 is a Vertical 'Y of Fig. 1 `to represent the horizontal axis 'and above it I rlocate the Vpoint S say onefourth inch therefrom, this distance corresponding to the intended elevation of the 'iok light source above the'relector axis. It will he understood that this displacement may be either less or greater than the amount I have suggested, and will also depend upon the fo cal depth of the curve. If made too great, diiliculty willbe experienced in merging to gether the differenty surfaces inasmuch as they will'be severly warped; if inade too small, the desired light control will: not be obtained. The present drawings are exag- `gerated in all respects in order to show the k theory of operation within the small scale permitted. Y. y y

Through the point S I draw a vertical line two inches long ending at the axis at 2. This line corresponds to the parametery of a parabola kand its upper end 3 is a point of the curve at which its inclination to theaxis 1-1 is substantially 45. Also at a point in the rear of the line 2--3V I draw a parallel line D-D at the same distance from the `point 3` as Sis distant from 2. -This line correspondsto the directrix of awparabola,

and the procedure thus far oonformsexactly "tothat which would be followed if a parabola` were to be drawn aboutv the point 2, with a focal distance of one inch. 0f course y do notlmt myself to this size. f,

Howeven ity 'he'peintS be considered as light. aurea than its vireaaifijsaea along 75 developed* as follows:`I drawy the line 1-1 V the axis 1 will depend upon the angularity with which the rays strike that axis. For

. example I now draw an inclined line through vfbcusds 41 andidirecbrix is Iithenrdraw another inclined line g through the-point* S intersecting theaxis at 6, and

mlso'draw a correspondingy directrix G-G behind DL-D'asthe pointf-lies in front on the point 2. On this line I then find the point 7 which is equidistant from the point 6 andi'fromthe line G-G, the point 7 being upon .as parabolawirhosel focus is 6; andwhose directrix is G-G. I repeat the sameper- "formance for a suicient number-of other linesto locate other points 8, 9, etc'. and thus plstian accurate curve between the paramexmd the 'vertex z yIl then-draw an inclined line j through the :point S intersecting theaxisint 12- between the parameter and the-vertex and tof accomy it'I dra/w afperpendicular J-J as far in front of the line` D-Y-D as' 12 is behindV 2, after whichfI find the point v13I on this line which is-e'quidistant from the point 12 and located on: a pardsolwwhoseffmuaie 12, Y whosedectric: is\.l--Jl This-is repeated for the lines E and and `giving points 14, 15 andres many other vtimes vas desired `after which av curve Y is drawn connecting the poires-3, 5, 7, 9, 11, 13, 15.` i "To plat'the line/below the axis 1I draw a second straight lline---20V as in Fig. 2. and place at one-fourth inch Vabove it (or whatever distance I previously employed) a point S i the-point 21 andy I alsodraw asecond.

fine an accurate curve.

Iiromi which .I dropI a perpendicular p intersecting the axis at 21; and on thisiline at `about two and one-fourth inches (more or desks, but preferably alittle more Ythan the distance 2-3 fora reasonto be explained hernaiiter) below theline `I locate the point 22-whichis apoint on the curve. Also I drop the/perpendicular P-P- so ylocated that the 'point 22 shall beequidistant from 21 and from P-P. l f

lI then .draw an' inclined lineq'through the point S intersectingl the axis 20.at 23behind er- 'cularQ-Q the same distance in ront oitIL-P as 23-isbehind. 21.r Onitheline I f themlbcatathe point 24 equidistantifromxt e point 23 andy from' the line-Q-eQ. After 11epeating this witltother lines r, t, etc. IY find' the peints 26,- 28, etet-sucientdn numberwto. de-

I draw other lines as u, and o intersecting the axis in front of parison.

the point 21 and for each I draw a corresponding perpendicular as U-U, V-V an equal distance behind the line P--P thus finding the points 30, 32, etc. in the same fashion. I thenv connect the points 22, 24, 26, 28, 30, 32 rodncing the curve Z.

, his particular curve 1s mathematically known as a cubic and when accurately made y is defined' by the equation:

' yvcyz4pwy+4cm2=0` wherein p is the-abscissa and c the ordinate of the point S or S", but it'can be demonstrated that throughoutaconsiderable arc the sameis practically indistinguishable from the portion of aparabola lying between its vertexl and parameter, the axis of said parabola passingfthrough `the point S or S and inclined forwardly and downwardly so as' to make an. oblique angle with the constructionV faxes 1 1 and v20-,20 respectively. Such parabolic axis isindicated at l'OO'in 1 and 101 in- Fig. 2.

According to my preferred species the re- Yiiector to be made from these curves has a .central vertical section made by assembling patentdrawings areentirely out of proper` tion-in order to produce suflicient separation of the diderentpoints and lines for ready'refference).y If. a lightsource A be located at any point between Sand S', all rays falling on Y will be reflected forwardly andy downwardly as shown at C.' Indeed this downward deflection is so great as to render it desirable to tip the reector upwardly as regardsthehorizontal lineYH-I-I. rIhe dotted line F in Fig. 3' indicates atnue parabola drawn about the axis 20 for purposes of com- I Will now describe'th'e Inode whereby I apply my improvedy curves to the metal tool whereby this reflector is made. I first' take a suitablefblock. of metal shown by the dottedoutline40 in Fig. 4 and on the one side yI-turnk a cylindrical vboss 41 while the oppo- Asite .portion ofthe block is formed by a' suryfecoof..revolution ofthe portion Z of the curveV already, described', the axis 20-20 beingicoaxial with` the* boss 41 and with the axis'of revolution; This produces a mushroom-shaped metal block which is now shiftedbodily laterally to a new axis of revolution 42e-4,2' parallel to but spaced from the axis -20-20 and the block is again machined to vconforrnto the surface of revolution oi.: the same curve about the axis 42 Wit-lil a radius equal to slightly less thanfthe sum of the y K ,ldisplacement42- i plus the previousfradius. While in thispositionlA cut into the block at one side throughout the arc indicated approximately at y413--43 in Fig. 6, thereby slightly `flattening the block on one sidevand taking off a .comparatively thin layer indi-` catedv at thebottom of Figs. vand 6.," -This accomplished l shiftthe block `still further `illthe same direction-and; again turn it about' the axis 45, parallel to the firsty axisy the lamp is to diverge from horizontal. but displaced yet further yin the `same direction,-and cause the same to conform throughout a yetnarrower area vto the surface of revolution of the 'same lcurve aboutLk a .radius similarly increased. In this way `I removea yet narrower regionrepresented by n properly,y chosen,

` 'much' smaller than extendv over even 40 y"Either condition isequallyy satisfactory since the'arc in Fig. 8. A still greater number of settings can be .made if. desired,

`but isunnecessary. Indeed l' have hadexcellent results with only a single offset'cut- I nowk oisetthe block in `the oppositel direction to an. axis 4'8--48'and machineit :to

` conform lto the'. surface `of revolution of the 'curve Y; about this new axis, the radius of vrotatlon'being increased bythe distancebetweenQO and 48. If this displacement is over only a partfof itscircumference, the

bottomy portion ofthe block .swinging inside` this new surface o f revolution. In the embodment hereillustrated the curve Y is comparatively grcsttl verticaly displacement ofthe points S, S', and for this reasonthe cutextends more than a halfcircumference,

from 49-49. In actual `practice withthe' measurementsihere indicated the ycut will not a i sem1-circumference.

s the side wings` hereafterv described willA fill fthe gapvif such exists. is agai-nfshifted toanaxis 50 yet'further displaced` and is again machined to thefsame strip being cutfalong y punchl as indicated by the arc 51-51 kin surface' of revolution about a similarlyincreased radius, only a comparatively narrow the extremetop of the Fig.12." i,

The block is now shifted to a new and very eccentric s axis `52, klocated somewhat below the axis`20V and` very materially to one ,y side, anda side wing lturned throughout the slightly shaped "54 symmetrically' -arc 53-53e'xtending from the largest portion ofthe die tto a point'substantially oppo' site the` parameter.` This wing will appear flattened and lsomewhat wedgeas indicated at X in. Figfl; after which the block is ;again shifted to the axis locatedas regards the axis y, 52 and corresponding `to thearc55-5'5- lItv will beinecessary to ll'the'se various sections, if the work has been carefully done asherein directed, will merge together with very little unevenngess.

smooth down the the block will bev `surfaced the lcurve Zx owing to the;`

Thereupon the block meeting edges with a fine file but the only Vcarenecessary in this regard-is not to dress f the same too much, merely to removeroughness and produce a smooth blending. The f block is now'mounted in a 'base plate '56 shown in Fig. 13 yhaving a shank 57 adaptedto fit the socket ofthe punch press plu-nger,l the/facel and back of this base plate bein f inclined the amount by which the axis o The punch is removably secured to thisplate so boiler plate is amply sufficient for this ring.

. The absence of any refentranty angles or depressions in the vsurface of the punch dispenses with the need for a receivingmember which shall conform closely therewith, in otherv words a bottoming die. The reflector produced by Figs. 14

"strokeof the tool,V the edges ofthe plate being meanwhilegripped against the ring 61 in the manner well known to all those Lskilled inthe art vof metal drawing. A ypor- ,tion ofthis metal is left as at 65 to jform a s tijfening rim or flange trimmed to circular shape, *while* the heel of the reflector is provided with anv aperture VVfforthe reception of the lamp socket, the same bein locatedisuiiciently above the axis 20-20 to ring the light source the desired distance therefrom.`

It will be understood that-I donot limit myself to lany one relation ofv distances or ratio between the upper and lower curves "orfdisplacement of the foci of said curves or in anywise except deed rit will be noted that if these directions be accurately followed ythe axis 1-1 vand 20--20 will overlap each other by a short distance. This is no practical detriment but can be avoided by producing the original v blank about an axis located somewhere between the lines 20e-20 and 42-42 in Fig. 2. `The effect of this is to cause the line20-20 to vdescribe a cylinder of revolution whose of the blank. If this be done. at the start, f

then Vthe final punch will .exhibit the exit section shown in Fig. 3; if it be not done the device will be narrowed by this amount, although if properly designed the light will still be acceptab1e`- This is only a working allowance such as any carpenter must pro'- vide everytime he saws a board, but my invention is notrestricted to-such niceties al' "though the accuracy ofthe result is imn diferent angle from that originally exhibited namely along thistool is illustrated in y and 15, and `is made by a single whose exterior is mired thereby. Also I .have described a device made by swinging the blank vabout nwousaxes 20, 4,2, 45, 48, 5o, 52,551, n

otgwhich are parallel-to eachother which 1s extremely convenient in practice since inperinigts the tool to bemadeon a common Vlathe Ymerely byshifting the block about onthe I-olam 1s: Y

u., 1. A Onepiece metal lpunch for reflectors buying its Surface convex at all points and halting' its diffent vregions definedA by sur- Smale Flam.

fwso revolution about a yplurality of differpt longitudinal aies.

. 2. Acne-.piece metalrpunch for' reflectors ,kening its surface convex aft1all points and having its different regions defined by suri WBS of revolution aboutra plurality of longitlldnal axes, 'all 0f which are located in a A ene-,piece metal .punch for.' reflectors `opposed regions o which are defined by surfaces of revolution about dlfferentlongitu- Adine) axlesof curves which are parabolic as regprds afocalpont displaced fromall such axes.

(i. Acne-piece metal punch Y for reflectors, `bnfmg'theportionsupon yopposite sides of its Vlurinoipal axis denedby Surfaces of 4revolu- -timf dissimilar curves abouteccentric axes.

v5, A metal punch forreileetors havingva portion corresponding to a Surface defined b the rotationof asegu'lent ofl a parabola ,about an axis inclinedto the parabolic axis.

6. A metal'. unch `for reflectors bavng'a particu defined as the surfaceI of revolution e nt of a parabola about ,an axis of e a;

signature.

. 8. A blaterally symmetrical metal punch' for reflectors having its cross section defined by a pair of opposed semiovalsv of unequal curvature, the ends of saidseiniovuls being joined by arcs Whose centers lieiat the same side ofthe longitudinal axis of the oval and upon opposite sides of the transverse axis'.`

9. A bilaterally symmetrical `metal punch 'for reflectors Whose lateral regions are dened by surfaces of revolution about a` pair of spaced axes and whose intermediate 1regions arev defined' by sur-faces of revolution about a plurality of parallelfaxes all ofwhieh are contained in a plane `perpendicular to the plane which contains the irsttiveo,aires` 1Q. Ay `bilaterally symmetrical `onepsse metal punch for reflectors. having opposed portions defined by 'surfaces of revolution about a'plurality of parallel longtudinalfaxes all of which -are vcontained in. a single, plane and havin its lateral portions connected'by surfaces o' revolution .about axes displaced upon opposite sides of such plane. u l

1l.y A one-piece metall punch vfor automobile headlight reflectors having external portions defned by surfaces of revolutioniabout ases which are oblique to theaxis oi the punch 12,A A one-piece'nietalpunch for automobile ;reectors,'t ,he punch axis oblique to the axisof the curve which defines the releetor surface. A p

In testimonywher'eo, I hereunto ax. my

' Y, y WILLIAM-H. Wovon. 

